All truss foundation unit, method of making the same and foundation unit kit

Abstract

An all truss foundation unit, method of making the foundation unit, and a foundation unit kit. The foundation unit is formed of multiple cross trusses interconnected by bridging top and bottom side rails. This results in a flat surface on both the top and the bottom of the foundation unit. The kit is formed of a plurality of the trusses and four side rails, with the trusses and side rails being oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with at least some of their flat sides in contact with one another. When the foundation unit is constructed, a truss locator guide is provided on at least two of the side rails, and the cross trusses are oriented in a parallel, spaced relationship in accordance with the truss locator guide.

What is claimed is: 
     
       1. A foundation unit for supporting a mattress, said foundation unit comprising:
 a plurality of elongate cross trusses, each cross truss extending between a first end and a second end, each cross truss including a bottom slat having a first end and a second end and a top slat having a first end and a second end, said top slat having a generally flat top surface, said top slat being spaced apart from and above said bottom slat, each said cross truss including a first top notch at said first end of said cross truss adjacent said first end of said top slat, a second top notch at said second end of said cross truss adjacent said second end of said top slat, a first bottom notch at said first end of said cross truss adjacent said first end of said bottom slat, and a second bottom notch at said second end of said cross truss adjacent said second end of said bottom slat; 
 a first bottom side rail and a second bottom side rail, each bottom side rail having a first end and a second end, said first bottom side rail adapted to be located in said first bottom notches of said cross trusses, said second bottom side rail adapted to be located in said second bottom notches of said cross trusses; 
 a first top side rail and a second top side rail, each said top side rail having a first end and a second end and a generally flat top surface, said first top side rail adapted to be located in said first top notches of said cross trusses with said flat top surface of said first top side rail being generally coplanar with said flat top surfaces of said top slats of said cross trusses, said second top rail adapted to be located in said second top notches of said cross trusses with said flat top surface of said second top side rail being generally coplanar with said flat top surfaces of said top slats of said cross trusses, said flat top surfaces of said top slats of said cross trusses and said flat top surfaces of said first and second top rails forming a generally flat top surface of the foundation unit adapted to support the mattress; and 
 wherein each cross truss includes a pre-stress and at least one center support located between opposite end supports, said pre-stress comprising said at least one center support having a vertical dimension greater than vertical dimensions of said end supports. 
 
     
     
       2. The foundation unit of  claim 1 , wherein each said bottom slat of said cross trusses includes a generally flat bottom surface, said first and second bottom side rails each including a generally flat bottom surface that is generally coplanar with said flat bottom surfaces of said bottom slats of said cross trusses, whereby said foundation unit may be inverted such that said coplanar bottom surfaces of said first and second bottom side rails and of said bottom slats of said cross trusses are adapted to support the mattress. 
     
     
       3. The foundation unit of  claim 1 , wherein said top slats of said cross trusses have a first width, and said bottom slats of said cross trusses have a second width, said first width being wider than said second width. 
     
     
       4. The foundation unit of  claim 1 , wherein said center support and said end supports of each said cross truss extend between said bottom slat and said top slat of said cross truss. 
     
     
       5. The foundation unit of  claim 4 , wherein a first end support of each cross truss extends outwardly beyond said first end of said top slat of said cross truss to form said first top notch, and said first end support extends outwardly beyond said first end of said bottom slat to form said first bottom notch. 
     
     
       6. The foundation unit of  claim 5 , wherein said first top side rail is adapted to be coupled to a top end of said first end support of each said cross truss, and said first bottom side rail is adapted to be coupled to a bottom end of said first end support of each said cross truss. 
     
     
       7. The foundation unit of  claim 5 , wherein a second end support of each cross truss extends outwardly beyond said second end of said top slat of said cross truss to form said second top notch, and said second end support extends outwardly beyond said second end of said bottom slat of said cross truss to form said second bottom notch. 
     
     
       8. The foundation unit of  claim 7 , wherein said second top side rail is adapted to be coupled to a top end of said second end support of each said cross truss, and said second bottom side rail is adapted to be coupled to a bottom end of said second end support of each said cross truss. 
     
     
       9. The foundation unit of  claim 4 , wherein each said support of said cross trusses comprises a block support. 
     
     
       10. The foundation unit of  claim 1 , wherein the plurality of elongate cross trusses includes at least three cross trusses. 
     
     
       11. The foundation unit of  claim 1 , wherein said cross trusses are all constructed substantially identical to one another. 
     
     
       12. The foundation unit of  claim 11 , wherein said first and second bottom side rails and said first and second top side rails are all constructed substantially identical to one another.